Apparatus for cell construction



1963 J. v. CARLISLE ETAL 3,111,770

APPARATUS FOR CELL CONSTRUCTION 2 Sheets-Sheet 1 Filed Nov. 21, 1960 m. S L mi CM wiw sw Nov. 26, 1963 J. v. CARLISLE ETAL 3,111,770

APPARATUS FOR CELL CONSTRUCTION Filed Nov. 21, 1960 2 Sheets-Sheet 2 II INVENTORS JAMES v. anus/.5

THECDORE M. ARA/0L0 F IG. 2 ar ATTORNEY United States Patent 3,111,770 APPARATUS FOR CELL CONSTRUCTION James V. Carlisle, Baton Rouge, La., and Theodore M.

Arnold, Punta Gorda, Fla., assignors to Ethyl Corporation, New York, N.Y., a corporation of Virginia Filed Nov. 21, 1960, Ser. No. 70,893 2 Claims. (Cl. 33-180) This invention relates to a new and novel method for the construction of electrolytic cells, and in particular it relates to apparatus used for the construction of these cells.

The manufacture of sodium and other alkali metals is carried out in an electrolytic cell basically similar to the Downs cell described in US. Patent 1,501,756. Briefly, the cell includes a housing containing one or more cylindrical anodes each of which is projected into openings contained within, or is in other words surrounded by a cylindrical cathode. In the annular space which is formed between an anode and the surrounding internal surface of the cathode is positioned a foraminous diaphragm sup-- ported from above by a collector. The collector, a unitary assembly, includes an outlet port for removal of the gaseous halogen, and also an annular inverted channel for manifolding and for the removal of the alkali metal. This collector is supported by a frame which in turn is attached to and supported by the cell housing.

The concentricity and vertical disposition of the surfaces of the anodes with the surrounding diaphragm and surrounding cathode surface is an important attribute of a property constructed cell. Attaining this objective has been a long standing problem in the industry. Inherent difficulties in the construction of these cells has been the lack of a suitable method for positioning the cathode with respect to the anode, and for positioning the diaphragm within the annular space between anode and cathode. Because the cathode and the diaphragm surround substantially the entire length of the anode, it is quite difiicult to position the diaphragm concentrically between the cathode and anode within proper tolerances so as to provide a cell capable of the most efiicient operation. The difficulty in maintaining concentricity between anode, cathode and diaphragm can be appreciated when it is noted that ordinarily the lateral distance between the anode and cathode is of the order of only 1 /2 inches as compared with the entire length of the anode, which is about 3 to 4 feet or more in length. In addition, for best operation the diaphragm must be inserted equidistant from the anode and cathode over the entire length of the anode. Prior methods employed for achieving this result have not been adequate. Generally speaking, the life period, that is the time period of operation before the cell need be broken down for rebuilding, has been erratic and necessitated completely dismantling the cell to replace the diaphragms. Such dismantling and reconstruction, in addition to being inherently expensive, also results in reducing production capacity of a plant. This arises from the fact a shop or plant has a certain number of stalls or locations for occupancy by as many cells; when a cell is being torn down and rebuilt, it is then not possible to merely insert a spare into that operating space.

Until the present invention, the techniques in cell building left much to be desired, as above explained. Consequently, it is an object of the present invention to provide apparatus for the rapid and accurate construction of an electrolytic cell. A further object of this invention is to provide apparatus to be employed in constructing an electrolytic cell which will provide a cell having a longer life, higher efiiciency, and increased productivity. Another object of the present invention is to provide apparatus for the accurate positioning and attachment of an upper cell shell surmounting a lower cell shell and the 3,1 l 1,7 70 Patented Nov. 26, 1963 establishment of reference marks having a defined spatial relationship to a previously established anode-cathode configuration of an anode-cathode cell base assembly. Other objects will be apparent from the discussion hereinafter.

The apparatus of the present invention is capable of assuming a variety of forms, and can be used in conjunction with other apparatus, as will be readily understood from the details given hereinafter and in the accompanying figures wherein,

FIGURE 1 shows in exploded fashion the major components of a cell, the sequence of assembly of the components into a completed cell, and the relation of the apparatus of the present invention to other apparatus and to the several major components or sub-assemblies of a cell, and

FIGURE 2 is an isometric view of an apparatus, hereinafter termed Jig E, which provides for the accurate positioning and alignment of an upper cell shell upon a lower cell shell. The apparatus also provides for establishing alignment or reference marks on the upper cell shell, said reference marks having and providing an explicit spatial relationship, particularly to the anodes of a previously established cathode-anode cell base sub-assembly to which the lower portion of a cell shell has been added.

The apparatus, Jig E, comprises a top plate and a bottom plate which are separated and rigidly positioned in parallel planes so that when the lower plate is finally and properly positioned with respect to the anodes of the cathode-anode cell base assembly upon which the upper cell is to be installed, its registration will be preserved in the top plate, or in a plane corresponding generally with the uppermost portion of the upper cell shell which is added. Thus, the plates are fixed apart by a plurality of columns. The lower plate is provided with registration means, which can consist of a pair of registration holes, for orientation of the device upon the anodes of a previously constructed cathode-anode cell base assembly. The upper plate is provided with means, which can consist of two pair of registration flaps, for indexing the upper portion of the added cell shell as by locating indicia marks thereupon to preserve the relationship between the cell shell and the anodes of the cathode-anode cell base assembly. Having established this relationship the jig can be removed and the cell completed.

It has been found that the apparatus of this invention, particularly in combination with other apparatus, provides an eflicient means for the construction of an electrolytic cell whereby the criticality of the positioning of the cathode With respect to the anode, and the diaphragms with respect to the cathode and anodes, is achieved. The apparatus eliminates incorrect alignment of these integral parts which results, for example, in burning of the diaphragms and thus causing loss of production and unnecessary dismantling of the cell, which must be reconstructed. By the use of the apparatus of this invention, the efliciency of the cell is considerably increased as evidenced by the fact that production is increased for a given current input. In addition, the average life of the diaphragm is appreciably increased, thereby reducing loss in production time.

The construction of a completed cell includes two major assembly sequences, the assemblies so-made being combined into a completed cell. One sequence of assembly operations permits formation of the lower portion of a cell. This sequence of operations thus provides for the formation of a complete base assembly by the addition of anodes to a cell base, then for the addition of' a lower cell shell portion, then for the addition of a cathode, then for the addition thereto of an upper or final cell shell portion, thus completing this major assembly.

Another sequence of assembly operations includes assembly of a collector and collector support frame to form a sub-assembly, and then the addition of diaphragm screens to that sub-assembly to form the upper portion of a cell, the second of the two major assemblies. These two assemblies are then combined to form a completed cell.

This entire sequence of assembly operations is schematically illustrated by reference to FIGURE 1 which show the flow of separate cell components into subassemblies and the relationship of these components and sub-assemblies to the figures of the present invention. Referring to FIGURE 1, a set of anodes and a cell base are combined, using Jig C. The base assembly thus formed is then combined with a cell shell portion. part of the cell lining is then added, and a cathode is then fitted to this base sub-assembly using a Jig D to provide proper spatial relations. To this assembly is then added an upper cell shell using Jig E to provide means for correct alignment. This sequence of operations completes the formation of one of the two major assemblies, viz., the formation of a complete base assembly, or the lower portion of a cell.

The other major sequence of assembly operations involves firstly the combination of a collector and collector support frame into a sub-assembly, using Jig A. This subassembly and a set of diaphragms are then combined by the use of another apparatus, Jig B. This completes the second major sequence of operations and provides for the formation of a collector-collector frame-diaphragm assembly, the upper portion of a cell. This assembly is then transportedin a transport Jig F and is combined with the base assembly to form a completed cell.

The apparatus, Jig E, employed for positioning and alignment of the upper cell shell with respect to the cathode-anode cell base assembly, shown in FIGURE 1, is described by reference to FIGURE 2. FIGURE 2 shows in detail, Jig E, which is used for the accurate aligning and positioning of theupper cell shell with respect to the cathode-anode cell base assembly. Referring to FIGURE 2, this figure is a partially sectioned elevation showing a portion 175 of the upper cell shell, the previously aligned anodes 131 131 131 and the Jig E.

The Jig E includes generally a box-like frame including a base plate 161,, corner columns 162, and a .top plate 163. The corner columns 162 project below the level of the base plate 161, thus providing legs for supporting the jig, when not in use, Without resting it on the base plate 161. The top plate 163 and base plate 161 are positioned in parallel planes. The base plate 163i is provided with two registration holes 164,, 164 these holes being centered at a distance corresponding to the distance of registration or alignment bosses 147 of the Jig D.

The upper or top plate 163 has a plurality of holes 165 therein, and a center hole 166 rimmed with a machined surface plate 167. At the corners of the top plate 161 are four adjustment screws 168 168 16 8 168 actuatable by hand-wheels 169 16 9 169 1692;. Attached to the sides of the top plate 163 are two pairs of registration flaps. One pair 17%, 17%;), are hinged to gussets or extensions 171 171 and project, when extended, horizontally from the top plate 163. The other pair 172 172 are also hinged to extension plate 173,, 173 When extended, this pair projects to a position in a plane slightly below the plane of the top plate 163.

In construction, the upper portion of the cell shell 175, shown here in partial section, is first rigidly attached to the lower cell shell 148 portion in general alignment determined by the cell rim 176. The Zbars 177 177 are then temporarily attached to the shell rim 176 and a horizontal disposition provided by shims, not shown, when required. The Jig E is then gently lowered with the adjustment screws 168 extended as far as possible below the top plate 163. The jig is initially supported by the adjustment screws the engaging four extension plates 174 174 inwardly projecting from the shell rim 176 The jig is then further lowered by retraction of the adjustment screws 168 until the bottom surface of the base plate 161 rests on the pillow blocks M6 forming a portion of another jig, Jig D, used for the alignment of the cathode assembly upon the anodes 131 of an anode-cell base sub-assembly. Generally the previously established horizontal disposition of the Jig D thus provides horizontal alignment of the Jig E, though any necessary corrective adjustment can be made by the adjustment screws 168, the disposition of the Jig E being ascertainable by a level test of the machined plate 167.

The horizontal extension plates 171 171 are then turned to rest above the Z-bars 177 177 and these bars are s'lidably adjusted to register previously cut notches 178 173 in the Z-bars with the indexing slot of the extension plate. The Z-bars 177 177 are then securely bolted to the cell shell rim 176 The second pair of extension plates 173 173 are then extended and registration marks 17%, 179 are scribed on the cell shell rim. Thus two lines are established with reference to the upper cell shell, having a precise relationship to the remainder of the lower cell assembly. The Jig E, as well as Jig D referred to heretofore, is then removed from the cell assembly, and a refractory lining is built up in the interior to the upper limit of the upper cell shell. This completes the formation of a bottom assembly for a cell. The complete base assembly thus includes an entire assembly of the anodes, the cell base, the cathode and a complete cell shell and lining therefor. To complete the cell all that remains is to attach an upper cell assembly, including the collector, collector frame, and diaphragms. This is done by the use of further apparatus, Jig F, which i provided for joining the two assemblies cited.

From the foregoing, it is seen that the use of various apparatus provides for the construction of a cell having a continuous explicit relationship between the collector frame, collector, diaphragms, anodes, and other portions of a cell. These relationships are established and preserved from the beginning of construction through to the final assembly step. Further steps to render a cell operable after assembly of a complete base assembly with a collector-collector frame-diaphragm assembly would include the connection of an appropriate chlorine line to the collector opening, and the attachment of the necessary electrical connections, etc.

In careful comparison of the performance of a group of cells constructed with the apparatus of our invention with performance of a group constructed according to previous methods it was found that the former group provided an increase of approximately 1.5 percent in current efliciency. In addition, it was found that the average effective life of the former group of cells was a significant improvement over the preceding practice, particularly with respect to the diaphragm life. Since the cost of construction of cells with the present apparatus is substan tially the same as by the former practices, it is apparent that our apparatus is highly beneficial and economical.

Having described the apparatus of our invention in some detail and the manner of its use, what we claim is:

1. Apparatus for the alignment and assembly of an upper cell shell to a lower cell shell surrounding the anode-cell base sub-assembly to form a. substantially complete lower sodium cell assembly comprising a frame including a base plate and a top plate in parallel planes, said plates being separated by a plurality of columns, said base plate being provided with at least two registration holes for alignment of the upper cell shell with the cell base sub-assembly, the upper plate having at least three downwardly directed adjustment screws which are extendable and retractable within the plate so that the terminal portions of the screws can bear downwardly against the surrounding cell shell for supporting and leveling the apparatus upon the cell shell for eventual reception of the upper portion of the cell to form a complete cell, said upper plate also being provided with two pivotally connected extensible pairs of registration flaps for contact with the surrounding cell shell for establishing a precise relationship between the lower cell assembly and the remainder of the cell assembly.

2. Apparatus for the positioning and assembly of an upper cell shell upon the lower cell shell of a completed cathode-anode base assembly of an electrolytic cell comprising a pair of rigidly uniformly spaced apart parallel plates separated by four corner columns, the bottommost plate provided with two registration holes spaced apart and :diagonal to each other to serve as a means of reference for alignment upon the anodes of a completed cathode-anode base assembly, the topmost plate having at each of its four corners downwardly directed adjustment screws, adjustable by hand wheels, said screws being extensible and retractable within the plate so that the terminal portions of the screws can bear downwardly against the surrounding cell shell, two pairs of registration flaps hinged upon the top plate for contact with the surrounding cell shell for establishing a precise relationship be tween the lower cell assembly and the remainder of the 10 cell assembly. i 1

References Cited in the file of this patent UNITED STATES PATENTS 2,270,158 Baesgen et al Jan. 13, 1942 

1. APPARATUS FOR THE ALIGNMENT AND ASSEMBLY OF AN UPPER CELL SHELL TO A LOWER CELL SHELL SURROUNDING THE ANODE-CELL BASE SUB-ASSEMBLY TO FORM A SUBSTANTIALLY COMPLETE LOWER SODIUM CELL ASSEMBLY COMPRISING A FRAME INCLUDING A BASE PLATE AND A TOP PLATE IN PARALLEL PLANES, SAID PLATES BEING SEPARATED BY A PLURALITY OF COLUMNS, SAID BASE PLATE BEING PROVIDED WITH AT LEAST TWO REGISTRATION HOLES FOR ALIGNMENT OF THE UPPER CELL SHELL WITH THE CELL BASE SUB-ASSEMBLY, THE UPPER PLATE HAVING AT LEAST THREE DOWNWARDLY DIRECTED ADJUSTMENT SCREWS WHICH ARE EXTENDABLE AND RETRACTABLE WITHIN THE PLATE SO THAT THE TERMINAL PORTIONS OF THE SCREWS CAN BEAR DOWNWARDLY AGAINST THE SURROUNDING CELL SHELL FOR SUPPORTING AND LEVELING THE APPARATUS UPON THE CELL SHELL FOR EVENTUAL RECEPTION OF THE UPPER PORTION OF THE CELL TO FORM A COMPLETE CELL, SAID UPPER PLATE ALSO BEING PROVIDED WITH TWO PIVOTALLY CONNECTED EXTENSIBLE PAIRS OF REGISTRATION FLAPS FOR CONTACT WITH THE SURROUNDING CELL SHELL FOR ESTABLISHING A PRECISE RELATIONSHIP BETWEEN THE LOWER CELL ASSEMBLY AND THE REMAINDER OF THE CELL ASSEMBLY. 